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March 2016—Vol.39 No.3
CHINESE OVERVIEW REFRACTORIES SHANDONG HUAPENG - CHAIRMAN INTERVIEW A GLOBAL REVIEW OF GLASSMAKING
I N T E R N A T I O N A L
Glass International March 2016
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Contents
March 2016 Vol.39 No.3
WWW.GLASS-INTERNATIONAL.COM
2 Editor’s Comment
March 2016—Vol.39 No.3
5 International news
CHINESE OVERVIEW REFRACTORIES SHANDONG HUAPENG - CHAIRMAN INTERVIEW
13 Company overview: Shandong Huapeng A Chinese group with global plans
A GLOBAL REVIEW OF GLASSMAKING
I N T E R N A T I O N A L
Glass International March 2016
Our fresh breeze for all types of glass production
13
Float Glass
Fibre Glass Tableware Container Glass
Thin Glass
17 20
Chinese overview: China’s container industry set to rise to higher peaks Company profile: FERVER Federation proves that glass recycling is not a waste of time
Supplier profile: Zippe 24 A family affair
Front cover image www.eme.de
20
27 Lubricants Swabbing Robot lubricant success 28 History British Glass 30 Small is beautiful
Case study: Verallia Bad Wurzach 32 Verallia installs synchronous reluctance technology
Inspection 44 Improving the quality of hollow glass through inspection Plant technology 46 A production monitoring solution
Plus find us on Linked-In and Twitter.
@Glass_Int
www.glass-international.com
32
www.glass-international.com
24
Refractories 37 Recycling refractories 40 Analysis of glass defect compositions from AZS refractory
1 Glass International March 2016
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Editor’s comment
Greg Morris
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: Sally Love Tel: +44 (0)1737 855154 Email: sallylove@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com
Where have all the young people gone?
Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com Production Executive: Martin Lawrence Managing Director: Steve Diprose Chief Executive Officer: Paul Michael
I
www.glass-international.com
Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
t’s been an interesting month for me, mostly spent in a car or train, travelling to several meetings with prominent suppliers and leading figures of the glass manufacturing industry. These people are at the forefront of our business and represent a variety of sub sectors. They travel a lot, speak to plenty of people and generally have their finger on the pulse of the industry. Among our varied chats – which are always a pleasure – one concern alone stood out: the lack of young people entering the industry. The glass industry is not an attractive one to youngsters. Glass plants are hot, noisy and dirty places. Other industries, with minimalistic, air-conditioned offices and a glamorous end product such as the automotive industry in the UK, are regarded as cooler and cutting edge. One correspondent told me that the last innovation in the glass industry was 30 years ago with the introduction of the NNPD process. Where will the new ideas come from if young talent is snapped up by other industries? It is not all hopeless. Projects such as British Glass’ Glass Academy have raised the profile of glass in schools and encouraged apprentices to pursue a career in the industry. Other national associations should follow its lead. Glass is still regarded as a desirable industry in developing nations such as
China, India and the Philippines. Young, less weathered, faces were prominent at events such as Glasspex in India, the AFGM event in the Philippines and Glassman in Mexico. The exchange of knowledge and new ideas is as important as ever. If young people are opting to forge careers elsewhere, glass must make use of the talent it has if it is to retain its leading position. The forthcoming Glassman Middle East conference is one such event where suppliers and manufacturers will present the latest trends and innovations. The Middle East, with its flourishing youthful population, is an ideal market in terms of attracting young people to glass. It should follow the lead of the region’s aluminium industry, which has plenty of fresh-faced graduates working in it. Given the recent boom in activity in the MENA region, including the lifting of trade sanctions in Iran, the free to attend conference has attracted attention from manufacturers keen to visit the hollow glass industry’s most prominent suppliers. The event will welcome the Director of Iran’s Noritazeh and the Operations Director of Frigoglass’s glass manufacturing division as keynote speakers.
Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com
Official publication of Abividro - the Brazilian Technical Association of Automatic Glass Industries
Member of British Glass Manufacturers’ Confederation
China National Association for Glass Industry
United National Council of the glass industry (Steklosouz)
Glass International annual subscription rates including Glass International Directory: For one year: UK £164, all other countries £231. For two years: UK £295, all other countries £416. Airmail prices on request. Single copies £45. Glass International Directory 2015 edition: UK £206, all other countries £217.
Greg Morris Editor gregmorris@quartzltd.com
Quartz Glass Portfolio
Monthly journal for the industry worldwide
Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com
Directory 2015 Annual international reference source
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Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK.
Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 173180437.
Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2015 ISSN 0143-7838
2 Glass International March 2016
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International News
NEWS IN BRIEF
Vitro sales boosted 22%
Technology suppliers sign up for Middle East hollow glass event Several of the hollow glass industry’s leading technology suppliers have confirmed their presence at the Glassman Middle East event. German company Pennekamp and UK group Electroglass have each taken a booth at the exhibition. They will be joined by French inspection group Tiama, and Anderman Ceramics, who will both present papers at the parallel conference. Pennekamp manufactures equipment for thermal processes (lehrs) as well as other
product areas within the glass industry. Electroglass has been involved in electric glass melting technology since 1976. Its core activities are the development, design, engineering and supply of electric glass melting and conditioning systems and related equipment. Tiama is a provider of inspection solutions for the hollow glass industry and will provide an update about its vision product range. Anderman Ceramics’ Gary Hateley will present a paper
titled Supplying refractory insulation for furnace linings. Glassman Middle East is a free to attend exhibition and conference dedicated to the hollow/container/tableware/ speciality glass sectors. It takes place on May 10 and 11 in Abu Dhabi, UAE and visitors will include glass manufacturers from the region, associations and technology suppliers. For more information visit: www.glassmanevents.com/ mid-east
Iranian manufacturer Noritazeh confirmed as keynote speaker Iranian tableware manufacturer Noritazeh has been confirmed as a keynote speaker at the Glassman Middle East hollow glass conference. Noritazeh’s Director, Saeed
Kalafchi, will give a 20-minute overview of the Iranian glass industry and provide an update on Noritazeh and its recent developments. Other speakers at the hol-
low glass conference include glass container manufacturer Frigoglass, inspection company Tiama, Pneumofore, IRF Europa and French refractories group Sefpro.
Interglass and Pennekamp form LATAM partnership Mexican group Interglass has formed a partnership with German lehrs company Pennekamp. The new partnership will see Interglass introduce and push Pennekamp’s range of products and equipment throughout the entire LATAM region. Jose Luis Velez, Interglass Managing Director, said: “We’re very optimistic about
the success that this collaboration will bring to both companies, as Pennekamp’s top technology perfectly complements our solutions portfolio. “We are sure that this new partnership will be very prosperous and that it will maintain us on the right track to lead the LATAM market on behalf of all the companies that we represent and work with.”
Growth in its container and flat glass businesses helped Vitro grow sales by 22%. The Mexican company reported that the growth in the construction and automotive sectors as well as strong export and domestic sales had boosted business in the final quarter of 2015. Consolidated net sales increased 22.2% to US$229 million in the quarter, it reported in its quarter four 2015 financials. Vitro CEO, Mr. Adrian Sada Cueva, said: “The strong dynamics of the construction market driven by shortages in Mexico and the economic recovery in the US, coupled with the acquisition of new customers and increased exports of glass for the automotive sector, and strong sales volumes in the pharmaceutical industry were the main factors that boosted sales this quarter.”
Frigoglass terminates GZI sale
Frigoglass has terminated its agreement to sell its glass business in Dubai and Nigeria to GZ Industries (GZI). The agreement was signed with GZI in May 2015, but a condition of the terms was not met. GZI did not secure the necessary level of debt financing for the acquisition, as a result of a change in regulations that restricts the ability to leverage Beta Glass, and the adverse economic conditions in Nigeria. Amended offers were made by GZI, but these were declined by Frigoglass’ Board of Directors.
PPG sells PGW stake
PPG is to sell 40% of its stake in Pittsburgh Glass Works (PGW). The sale is in connection with LKQ Corporation’s plan to buy PGW, which is expected to be completed by the end of the second quarter this year. PPG has held a minority interest in PGW since 2008, when it completed the sale of its automotive glass and services business to PGW.
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International News
NEWS IN BRIEF
Borosilicate glass’ 125th anniversary
Exactly 125 years ago, Otto Schott, the founder of the technology group Schott, discovered borosilicate glass and created the basis for high-tech applications in the 21st century. The glass is used in a variety of applications, from streaming of sports events to high-tech material research. These modern applications would not be possible without the borosilicate glass to protect cameras or for use in neutron conductors.
Thai Glass forms partnership with Xpar
Thai Glass Industries (TGI) has joined forces with Xpar Vision in a stragetic partnership to provide hot end sensor technology to the global container glass industry. The partnership is the crown on the co-operation, which started two years ago between TGI, which is the container glass manufacturing subsidiary of Berli Jucker in Thailand, and Xpar Vision, based in The Netherlands. The collaboration began with an extensive trial of the Xpar Vision InfraRed Dual (IR-D) camera. The trial was executed at the TGI production facility at Saraburi. With the IR-D camera system all bottles are inspected in real time, to detect critical defects.
www.glass-international.com
Libbey reports 3.5% drop in sales in 2015
US tableware manufacturer Libbey reported a full year sales drop of 3.5% in 2015 compared to the prior year. In its full year financials for 2015, it said net sales decreased in the EMEA and Latin American region but increased in the US and Canada. It said sales performance in the US and Canada last year was led by a 7.5% increase in sales within the segment’s foodservice channel. For 2016 Libbey forecast a sales growth of 1% from $822.3 million to $830 million.
Ground clearing begins at Ethiopian bottling plant Atlas’ 100% owned subsidiary, East Africa Packaging Holdings (‘EAPH’), is building a glass bottle manufacturing facility 45km north of Ethiopia’s capital, Addis Ababa. The plant will have the capacity to produce 105 million, 330ml bottles a year. Named the ‘Chancho Project’, Atlas has commenced ground clearing at the site, and held a ceremony to commemorate the event (pictured, with Atlas’ CEO Carl Esprey pictured second from left). Commissioning of the facility has been scheduled for 2018, with full production targeted for early 2019. Levelling of the 5.5 acre site has begun and the topsoil has been stripped. The Chancho Project site is located in an established industrial area that is serviced by excellent road infrastructure as well as power. Preliminary assessments of potential sources and studies of local mining operations carried out confirm appropriate grades of silica sand and
limestone are available in deposits 30km away from the site. An initial pre-feasibility study was completed at the Chancho Project and returned positive results. A full feasibility study is now being conducted in tandem with local and international engineering consultants, which is close to completion. The total capital expenditure is estimated at US$42 million, to be funded on a staged basis by a mixture of debt from local development banks, other debt providers,
industrial partners and equity. For the last five years, due to increased consumer demand and a young demographic, Ethiopia has been attracting investment from international beverage companies, with more than $500 million invested to date. Beer production has been growing at a CAGR of 14.3% over the last 14 years, with an additional 47% capacity currently under construction. The demand for glass bottles is largely unmet by domestic production and is at present mainly satisfied by imports.
Record year for UK electric melting specialist UK-based electric melting specialist Electroglass has reported a ten-year record in its 2015 results. “Despite uncertainty and slow-down in a number of world markets, we have had an excellent year”, said Managing Director Richard Stormont. “All-electric furnace and forehearths projects for fluoride opal tableware glass, in south Asia in particular, have been significant contributors
to this, along with borosilicate electric forehearths work in the USA; gas-to-electric soda-lime forehearth conversions in South Korea; electric boosting projects in Indonesia and elsewhere; and continuing development and sales of our Precision Control Bubbling Systems. “Also holding up well are sales of hardware, notably the Molycool and Vertical Splashguard ranges of electrode
holders and our dry-type forehearth electrodes,” he added. “The rest of 2016 sees the commissioning of several recently supplied systems and work is expected to start on a number of significant new projects for the company.” Electroglass will be exhibiting at the upcoming Glassman Middle East show in Abu Dhabi, on the 10th and 11th May.
6 Glass International March 2016
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International News
Siam Glass’s vacuum system Production performance per IS line:
BEFORE 145
Weight (g)
AFTER 140
DEVIATION -3.35% 0.97% 1.30%
Speed (bottle/min)
515
520
Efficiency (%)
93.2
94.5
3.7 TPD saved/day/IS
7.200 more bottles/day/IS
Total of: 21.600 more bottles produced in the plant/day
Italian company Pneumofore has installed a vacuum system at Siam Glass’s Rojana plant in Thailand. The vacuum system, used in glass forming, has helped reduce the weight of bottles from 145 grams to 140 grams and means Siam Glass can produce 21,600 more bottles each day. Siam Glass runs three plants in Thailand, making
energy drink bottles of varying size. The challenge for Pneumofore was to reduce the container thickness and decrease the rejection rate of 150ml bottles by the use of vacuum. Only one of the three IS lines was modified and configured as a ‘test bench’ for vacuum. The results convinced the management to extend the use of vacuum on
to Lines 1 and 3 and it will also become standard at its other two plants. Three UV50 rotary vane vacuum pumps are constantly in operation at the Rojana plant. They ensure the exact vacuum level required on the moulding machines by means of variable speed drives and deliver a higher performance with minor power consumption.
Vetropack orders SIL system Swiss group Vetropack closed a deal with Vertech’ early this year to install SIL2016 in the company’s recently acquired Italian plant, Trezzano sul Naviglio. Vetropack bought the northern Italian plant from Bormioli Rocco in June 2015 in order to strengthen its position in the European market.
Trezzano sul Naviglio currently produces around 140,000 tons of glass packaging every year for the food and beverage industry, and used Vertech’ solutions for production line monitoring and quality control on some of its lines. Vetropack’s decision to extend SIL to the remain-
ing production lines and the mould department is part of the company’s corporate strategy to gain significant market share, as well as expand its current product portfolio and customer base. SIL2016 is scheduled for installation in Trezzano sul Naviglio before the end of the first quarter.
Orora to invest $42M Orora has committed to spending $42 million on additional glass bottle forming lines at its South Australia glass plant, to increase capacity. The increase in output will be approximately 60 million bottles per annum. To maintain production rates, commissioning will be progressive and is expected to commence in the
second half of 2016, with completion expected in the first half of 2017. Approximately 35% of the cash flow will be invested in FY16 with the balance in FY17. The company is also assessing a potential investment of a further $10-$15 million in an automated warehouse. Orora’s glass business
is experiencing increased demand within the wine segment, driven by the repatriation of wine that is currently bottled offshore. “The glass business is already in an oversold position, and this investment will further enhance Orora’s ability to service the increased demand from customers,” said Nigel Garrard, Orora’s CEO.
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International News
NEWS IN BRIEF
Glassman sign-ups
Mega Enterprises is the latest company to secure a stand at the forthcoming hollow glass show, Glassman Middle East. The company has taken a 54m2 booth at the free to attend hollow glass exhibition and conference. The company represents a number of leading European container glass suppliers, including Tiama, Antonini, Revimac, Ruitai and Messerssi. They will be joined by German group LWN Lufttechnik, which has taken a 9m2 stand at the exhibition.
Furnace life website
PaneraTech has released a dedicated website for SmartMelter, a technical solution for furnace life optimisation. SmartMelter provides asset management for glass melting furnaces. The website allows glass manufacturers to learn more about the technology and outlines service and licensing options. The website is www.smartmelter.com
Interglass gas crisis
www.glass-international.com
Gazprom Kyrgyzstan has threatened to turn off the gas supply to flat glass manufacturer Interglass. The gas company said it would disconnect Interglass due to unpaid debts amounting to 1,117,400,000 of Kyrgyzstan soms ($15 million). According to Gazprom Kyrgyzstan, it has not stopped trying to settle the matter out of court, and has tried to initiate meetings with Interglass. It has, to date, not turned off the gas supply due to the social importance of the plant.
Pneumofore
In the last issue of Glass International magazine in an interview with GIMAV Director Laura Biason, Pneumofore’s location was labelled incorrectly in a map of Italy. The company is based in the north west of the country, rather than the north east.
Bastürk Glass selects Sorg German company Sorg said it was honoured to have been selected as the furnace supplier by Bastürk Glass for its greenfield project in Turkey. Bastürk is a new player to the glass industry and is building a site in Malatya in the Eastern Province of Turkey. The new factory will go into operation at the beginning of 2017 and produce 300 tons per day of glass containers. Sorg said it ‘wanted to thank Y & H Foreign Trade Limited for its assistance in securing the order and Bastürk Glass for placing its trust in us’. The Bastürk delegation at the Sorg site in Lohr am Main, Germany
Heye welcomes Stölzle experts Heye International welcomed senior production experts from the Stölzle group to Obernkirchen, Germany recently to discuss their development priorities. Stölzle is an important customer for hot and cold end equipment and Heye’s technical team were on hand to discover the customer’s priorities.
Ten senior members of Stölzle’s multinational production team attended the meeting in Obernkirchen, where Gerd Müller, Cold End Manager, presented the group’s latest developments, including the creation of a centre of excellence for cosmetic flacons at the Masnieres plant in France. As well as discussing best
practice solutions for the glass container production process, the workshop addressed future inspection priorities. This included a debate about which cold end inspection functions could be moved to the hot end, the elements required in the ‘ideal’ inspection machine and the potential for automatic job changes.
Top 10 stories in the news Our most popular news items, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news r 1 Iran’s Nafis Glass commissions glass plant r 2 Borosilicate glass celebrates 125th anniversary r 3 Ground clearing begins at Ethiopian bottling plant r 4 Interview with Shandong Huapeng General Manager, Mr Zhang De Hua r 5 Wine and spirits help boost O-I volumes by 3% in 2015 r 6 Ardagh Glass launches updated educational programme r 7 Quantum and Interglass form partnership r 8 Impianti Novopac latest company to sign up for hollow glass exhibition r 9 Frigoglass terminates sale to GZ Industries r 10 Glass school in China Be first with the news! VISIT: www.glass-international.com for daily news updates
10 Glass International March 2016
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Chinese
Company overview: Shandong Huapeng overview
Mr Zhang De Hua is chairman and General Manager of Chinese container and tableware
A Chinese group with global plansgroup A Chinese
manufacturer Shandong Huapeng Glass.
with global intentions handong Huapeng Glass consists of Huapeng Glass (Heze), Liaoning Huapeng Guangyuan Glass, Anqing Huapeng Changjiang Glass and Shanxi Huanpeng Shuita Glass. It specialises in R&D, production and sales of all kinds of medium and top grade glassware and glass bottles. Its main bottle and glass production lines and ancillary on-line automatic inspection machines are advanced equipment that has been imported from the USA, Italy, Germany, France and Belgium, and are of the highest international advanced level. The company also has a Provincial Enterprise Technology Centre and a Provincial Glassware Engineering Technology Research Centre with R&D ability, A total of 37 types of its glassware products have won the design patent certification issued by the Sate Intellectual Property Office, and the product quality has reached the domestic leading level and an international advanced level. It is the main supplier to Metro, Wal Mart, Carrefour, Trustmart and many other well-known international supermarkets.
S
Could you please introduce your company, Shandong Huapeng Glass and your strategy at this time?
Could you briefly present the current Chinese glass packaging market?
What benefits has the Tiama equipment brought to Shandong Huapeng?
Mr Zhang De Hua: The Chinese glass industry faces strong consolidation, the new environmental regulations have made it difficult for small glass factories to survive. The market leaders will certainly shape tomorrow’s glass industry.
We have achieved a lot of quality inspection improvement, for example, we have drastically reduced the quantity of cracks. Our global product standard and our overall product quality have both surged. We are using the most advanced
Shandong Huapeng is one of China’s leaders in glass packaging and the largest manufacturer of crystal-like tableware. We have taken advantage of today’s industry evolution and our company has opened new factories all over China. At this stage, we already have more than seven glass factories. Our company strategy is to bring higher quality products to the domestic market as well as carrying on our strong development of international sales. For this reason, Huapeng chose to use international standard imported equipment and we voluntary selected international standard inspection equipment as well. In 2015, Huapeng upgraded one complete new production line with Tiama’s latest inspection machines MCAL4 (sidewall & dimensional), MULTI4 (finish & base) and MX4 (carousel technology) equipped with ATLAS systems (noncontact check detection). Before May 2016, Huapeng will install an additional 12 machines: MCAL4, MULTI4 and MX4 with ATLAS.
Continued>>
www.glass-international.com
Mr Zhang De Hua is the Chairman and General Manager of container and tableware manufacturer, Shandong Huapeng Glass. The company has its headquarters and two factories in Shandong, one factory in Liaoning, one in Shansi, one in Anhui and one in Zhejiang.
13 Glass International March 2016
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Chinese
Company overview: Shandong Huapeng overview
An overview of its headquarters in Shandong.
“The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our
”
www.glass-international.com
product safety.
technology for detection, which is the ATLAS system and it ensures a repeatability of the detection that we could not reach in the past. We are also monitoring and inspecting the glass thickness in our glassware, as a general results we have no broken ware delivered to customers. We have received appraisal from our most demanding North American foreign customers.
How important is automation and automated equipment to your company? Automation is very important for our company as it is directly linked with quality. Our customers are very demanding for quality, and automated equipment has helped us to achieve our productivity targets while improving our quality.
What is the Shandong Huapeng main range of products? Shandong Huapeng has positioned itself as one of the leaders for the production of wide-mouth jar packaging, as well as all kind of bottles shapes for wine, liquors and olive oils.
We manufacture for China’s market but also a large share of our production is for export market in the APEC regions. These containers require a high quality level of inspection. The Tiama inspection equipment has helped us achieve the highest quality standards required by our customers and ensures our product safety.
Finally, can you briefly tell me about Huapeng’s tableware capacity? Yes, that is right, Huapeng Glass is a leader for the production of crystal wine glass and lead-free wine glass. We provide our products to famous five stars hotels in China as well as export them worldwide, our main markets are South Korea, Japan, the United States, Canada and Russia. r
Shandong Huapeng Glass, Shandong, China http://en.huapengglass.com Tiama, Vourles, near Lyon, France www.tiama.com
The company has installed the latest inspection equipment from French company Tiama.
14 Glass International March 2016
Company profile shandong 2 pages.indd 2
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Glass is our Passion
Country profile: China
China’s container industry set to rise to higher peaks
P
roducing around 26 million tons per year, the Chinese container glass industry has more than 900 large, medium and small container glass producers, and grew at a CAGR of more than 12% from 2000-2014. Production figures for 2015 are not yet available, but it is anticipated that growth figures remained close to 10% on a year-to-year basis. The industry has achieved this gigantic growth on the back of brisk urbanisation, a rise in disposable incomes for a vast section of the population, and increased spending on food and beverages. An increased focus on healthcare has also been an important spur for the development of the industry. The top 10 provinces contributed 85% to the country’s overall container glass production in 2014, with most production based in the coastal provinces including Shandong, Zhejiang, Guangdong, Jiangsu and Fujian. The concentration of industry in these provinces is due to cheaper transportation costs for sea freight compared to land transportation. More manufacturing plants have set-up up along the coastal provinces to ship goods overseas, which in turn has also reduced freight prices.
Demand drivers Alcoholic and non- alcoholic beverages, food, and the pharmaceutical industry (in that order) are the largest demand drivers for container glass. Due to the complex nature of the Chinese container glass manufacturing industry, it is difficult to evaluate the performance of each subsegment on a numbers basis. This is due to the batch production nature of many of the mid and small scale producers, which often operate on a ‘by demand’ basis. Alcoholic beverages hold the largest share
“By 2022, China is expected to become the largest global consumer of food packaging, surpassing the
”
US.
of container glass consumption, despite the industry’s hold on beer packaging slipping for several reasons. Higher transport costs and a declining rate of returnable glass bottles are leading to higher costs when using glass bottles in the beer industry. The profit margins of glass-bottled beers are low compared to beer in cans, and as a result a numbers of brewers have turned to metal packaging. Consumers have also accepted canned packaging, particularly in retail consumption due to the convenience of carrying. After beverages, the food industry is the largest consumer of container glass and is likely to be the key driver of the sector in future years. The population has shifted to larger urban centres, which means large supermarkets selling packaged food items have replaced the traditional rural vendor or market stall selling raw, minimally packaged, items. By 2022, China is expected to become the largest global consumer of food packaging, surpassing the US. This is due to increased urbanisation, higher personal incomes and an escalating interest in packaged foods. PET packaging currently accounts for a large share of food packaging in China, but with an increased purchasing power glass is expected to corner a share in the industry. The performance of the container industry in Chinese pharma and cosmetics sub-segments has been particularly satisfactory, with the largest gains in the industry coming from these two sectors in recent years.
Overcapacity The establishment of a record number of new container glass producers and a huge capacity addition in the past few years has resulted in extensive overcapacity. Continued>>
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Ahead of the much-anticipated China Glass show in Shanghai, Seema Gahlut provides an overview of the Chinese container glass industry, which in recent years has grown at an astonishing rate.
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Country profile: China
S. No.
Company
Location
Production Capacity
Product Segments
1
Yantai NBC Glass Packaging
Shandong
140,000 TPA
Food & Beverage
2
Shandong Pharmaceutical Glass Company
Shandong
500,000 TPA
Pharmaceutical Glass
3
Linuo Glass
Jinan
140,000 TPA
Pharmaceutical Glass
4
Yantai Changyu Glass Company
Yantai, Shandong Province
500,000 TPA
Alcoholic Beverages
5
Rockwood & Hines Glass Factory
Jiaxing
120,000 TPA
Alcholic Beverages & Cosmetics
6
Kohler Glass Company
Jiangsu
80,000 TPA
Food & Beverage Industry
7
OMPI Pharmaceutical Packaging Company
Jiangsu
180,000 TPA
Pharmaceutical Glass
8
Shandong Yuncheng Ruisheng Glass Co., Ltd
Yuncheng, Shandong
160, 000 TPA
Beverage Industry
9
Xuzhou Dahua Glass Company
Jiangsu
180,000 TPA
Cosmetics and Pharmaceuticals
10
Yammamura Glass Qinhuangdao Company Limited
Jiangsu
200,000 TPA
Beverage Industry
11
Beijing Gerresheimer Glass Company
Jiangsu
300,000 TPA
Pharmaceutical Glass
12
Shandong Heishan Glass Group
Shandong
100,000 TPA
Beverage Industry
13
Zibo Baoxiang Glass Company
Shandong
120,000 TPA
Beverage Industry
14
Shendong Shenhua Glass Joint Company
Shandong
160,000 TPA
Food and Beverage Industries
15
Dalian Shengdao Glass
Dalian
120,000 TPA
Food & Beverage Industries
Table 1: Major Chinese container glass producers.
Lower than expected demand growth in recent years and the replacement of glass in some subsegments by alternative forms of packaging have led to an overcapacity. The overcapacity is more prominent in the mid and low end sub-segments of the industry.
Schott Xin Kang Glass Schott is a German manufacturer of speciality glass products and is investing heavily in China’s container glass industry. The company broke ground on the construction of a new pharmaceutical packaging plant in Jinyun County, Zhejiang province, in July 2015. The company already owns two production facilities in China, including an integrated production facility in Suzhou and one in Jinyun that was developed as a joint venture with Xinkang. Schott’s expansion plan also includes the modernisation and expansion of its existing facilities in Suzhou. It will invest $33 million in China in the next three years to increase its overall production capacity in the region by 50%. The new pharmaceutical packaging facility is being constructed at Schott Xinkang’s site in Jinyun. It will produce glass containers for injectable drugs, including vials and ampoules and is scheduled for commissioning in 2017.
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Shandong Pharmaceutical Glass Shandong Pharmaceutical Glass is a publicly held company engaged in the production and distribution of pharmaceutical glass bottles. The company was established in 1970 and has its registered office in Zibo, China. Shandong Pharmaceutical is one of China’s largest pharmaceutical packaging manufacturers. It produces pharmaceutical glass such as moulded injectable vials, glass tubing, ampoules and tubular vial for injection. It also produces container glass for cosmetics and the food & beverage industries. The company’s products are sold and distributed to domestic markets and to more than 1000 medical companies all over China. It also has a presence in USA, Europe, India, South Africa,
“[Schott] will invest $33 million in China in the next three years to increase its overall production capacity in the region by
”
50%
Australia, the Middle East, Thailand, Vietnam, Pakistan and Syria.
Shandong Huapeng Glass Shandong Huapeng Glass is one of the largest and most reputable container glass producers in the country. It comprises subsidiaries Huapeng Glass (Heze), Liaoning Huapeng Guangyuan Glass, Anqing Huapeng Changjiang Glass and Shanxi Huapeng Shuita Glass. It has an installed capacity of more than 240,000 TPA of container glass and more than 40,000 TPA of tableware glass.
Yantai Changyu Glass Company A subsidiary of the largest wine producer in China, Changyu Wine, Yantai Changyu Glass Company produces almost 90% of the bottles needed for its parent company’s wine packaging. Yantai Changyu Glass also meets the packaging glass demand of other major wine producers in the country. Yantai Changyu has an installed capacity of more than 600,000 tons of container glass a year. It has seven furnaces and 20 production lines in operation at two sites in Shandong province. The company is capable of producing products from 100ml to 6000ml with the blow-blow and pressblow technique. Continued>>
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Country profile: China
Xuzhou Rui Tai Glass Company
outgoing CEO, Al Stroucken: “In China, there are more than 1000 bottle makers and many sell at prices that didn’t make economic sense to us.” He added “We found it was difficult to compete profitably…with so many small players,” conceding that the effort to produce on a large scale for domestic customers, rather than multinationals with higher quality standards, was “a mistake.” In one of his last investor meetings, Mr Stroucken repeated the importance of the Chinese market. He said: “I would say long term, the trends in China still remain fairly positive. But, of course, we are operating from a much more restricted basis than we have had in the past. We have really focused on very few facilities that serve predominantly multinational or international customers because that is where we can get a satisfactory price level.”
Located in the Mao economic development zones in the city of Xuzhou, Jiangsu province, Xuzhou Rui Tai Glass Company is among the top ten container glass producers in the country. Claiming to have ‘best of its class’ equipment from some of the most reputable suppliers, Rui Tai operates six furnaces and 42 production lines to produce 500,000 tons of container glass per annum for beverage and food industries.
Kohler Glass Bottle Company Kohler produces 250 million glass bottles per year for the food and beverage industry and is located in Mapo town in Jiangsu province. The company produces container glass in flint, half flint, green and amber colours.
It can design and produce customised glass bottles according to customer’s requirements. The company also carries out deep processing, such as sand blasting, silk screen printing, glazed and transparent paints on glass bottles.
Shenzhen Tongchan Group Shenzhen Tongchan Group was founded in 2000 and has emerged as an important player in the country’s container glass production. The company owns Shenzhen Beauty Star, Zhaoqing Tongchan Glass Technology, Sichuan Tongchan Huajing Glass and Shenzhen Huajing Glass Bottle and has an installed capacity to produce 800,000 tons of glass through its subsidiaries. Its main businesses are high-end cosmetics and it supplies some of the top brewers in the country. Its major cosmetic packaging customers are P&G, Shiseido, Unilever, Avon, L’Oreal and Arrow. Its main beverage customers are Carlsberg, Heineken, Tsingtao, Pearl River, Haitian and other beer brewers.
Owens-Illinois Owens-Illinois (O-I), which had strengthened its position in the industry via the acquisition of two domestic companies in 2010, has scaled down its operations considerably in the country due to the issue of profitability. According to an earlier press statement of
“[O-I] has scaled down its operations considerably in the country due to the issue of
”
profitability
Chinese container glass production has reached an unprecedented level of production, although judging from recent trends in the Chinese and global economy there are tough times ahead. According to data reported by China’s National Bureau of Statistics (NBS), industrial production in the country rose 5.9% year-on-year in December 2015, slowing from a 6.2% increase the previous month. The manufacturing sector expanded the most by 7%, followed by mining (+1.4%). In contrast, electricity, heat, gas and water production and supply declined by 0.8%. From January to December 2015, industrial output rose 6.1%. On a month-on-month basis, industrial output grew 0.41%. Industrial production in China averaged 12.72% from 1990 until 2015, reaching an all time high of 29.4% in August of 1994 and a record low of -21.1% in January 1990. The industrial output of the flat glass industry dropped by 8.6% year-on-year, according to the NBS. The slowdown in the flat glass industry is a result of central government’s strong commitment to slashing excess capacity and discouraging zombie factories – those unable to pay their debt and survive without outside support – which face greater challenges to survive this year. Container glass demand will drop in future due to China’s economic slowdown. Container producers have already made production cuts as demand from end users has dwindled. Production levels in the segment have not dropped as sharply as those in the flat segment, where the temporary suspension in a large number of construction projects has led to a substantial fall in flat glass demand. But flat or low growth in the container sector cannot be ruled out. r
China Glass takes place this year in Shanghai between April 11 and 14th.
www.chinaglass-expo.com
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Slower growth
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Company profile: FERVER
Federation proves that glass recycling is not a waste Ferver’s member companies have invested heavily in machinery in order to supply glass manufacturers high quality cullet.
Greg Morris travelled to the Federation of Glass Recyclers’ (FERVER) headquarters in Brussels to meet its General Secretary Baudouin Ska. Mr Ska discussed the recent Circular Economy package put forward by the European Commission as well as the dramatic rise in glass recycling rates across Europe.
G www.glass-international.com
lass recycling collection rates in Europe have improved dramatically in the past 10 years. In autumn last year, the latest figures showed more than 25 billion glass containers were recycled in the EU, which is about 73% of all the bottles made in Europe. Terms such as recycling, sustainability and ‘being green’ have entered the public consciousness and most of us are aware of the benefits of recycling, whether it be glass, paper or food. It is no coincidence that the rise in recycling has coincided with the formation of the European Federation of Glass Recyclers (FERVER) federation, which was developed at the end of 2004 to represent the glass recycling companies of the continent. Promisingly, the amount of glass recycled in Europe looks set to rise even further: companies in countries where glass recycling is still a relatively new phenomenon have applied to join Ferver.
Once they are members they will receive the benefit of its expertise and be given information on how to develop their business. It has 40 member companies represented in 18 countries: 15 in the EU and three from outside the EU. Some 1900 staff from 66 recycling plants are represented by the federation with requests to join from companies in countries such as Turkey, Poland, Croatia, Romania and even Canada.
Background FERVER represents European glass recyclers. The majority of its members are from packaging glass, but there is a substantial number of flat glass recyclers who are represented. Like any traditional federation, it helps its members develop business, protects and informs them, and promotes their activities at an EC and Continued>>
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Company profile: FERVER
FERVER’s Secretary General.
national level. When new legislation is discussed at a European level, FERVER negotiates with the authorities to make it as acceptable as possible for its members. The new rules are then explained to members to ensure they understand and comply with the legislation at EU level as well as at national level. A current piece of legislation is the Circular Economy package, which is of huge importance to glass recyclers. The package, proposed by the European Commission, sets glass recycling rates at 75% across Europe by the end of 2025 and 85% by the end of 2030. The legislation, broadly welcomed by groups such as FERVER and container glass manufacturers association FEVE, has revised glass recycling targets in Europe. FERVER’s General Secretary, Baudouin Ska said they had to see if the targets were both ambitious enough and realistic enough. “There is currently a huge difference in recycling rates in the established countries such as France and the Benelux compared to places such as eastern Europe, where they are a long way from reaching even existing targets. “It will take time for these countries. It took a long time for them to realise the value of waste and it takes time, education and financial effort to organise a specific collection system to reach a valuable product for recycling.” In countries where recycling rates are low, financial measures from government, such as landfill taxes, will help boost recycling rates. Mr Ska has been in his current role for six years and said: “Eastern European countries are very active, but the problem they have is it is difficult to
get the source of the glass in their countries. They can perfectly recycle any glass that they collect but the problem is the input.” He warns of European legislation becoming too strict, causing the glass manufacturing industry to move to less regulated parts of the world. “It’s a fact that due to more stringent legislation we have seen the movement of glass factories from Europe to other parts of the world. Transport is not a cost at the moment so it is easy to import glass worldwide to Europe, but it is not suitable to send untreated collected glass all over the world. In the Circular Economy, where sustainability and proximity are key terms, it makes no sense to recycle material to send to other parts of the world.” Glass recycling rates vary greatly across Europe, from 97% in Sweden and 88% in Germany, to 38% in the Slovak Republic and 32% in Hungary. Work has begun to improve rates in those countries and one of the benefits of being a FERVER member is that different countries swap best practice ideas. The EU Commission in its Circular Economy package proposes to change the definition of recycling. At present, recycling is considered as the moment of collection, but the Circular Economy package has changed the definition and refers to the final recycling process, which means that the stream is re-integrated into the production chain. Mr Ska admits there is a lot of work to do in eastern European countries, but states that the majority of FERVER members are safe in terms of the Circular Economy package. “More than 90% of our members’ production is sold as end of waste, so we have already reached the end of waste status, so what we are selling is no longer waste but a product. That means recycled.”
Black glass The improvement in glass recycling rates in Europe has been obtained by close collaboration between glass recyclers and glass producers. Each glass manufacturer wants to reduce its energy consumption and CO2 emissions, so therefore asks for high quality input material. For recyclers, it has required investment in more sophisticated sorting machines to sort out the non-glass, such as ceramic, stone and porcelain (CSP), and lead content in both crystal glass and in television screens. One recent problem for recyclers has been the rise of trendy, colourful glass bottles, which are designed to stand out on the shelf against competitor drinks. Some bottles, such as black glass, are so dark they are considered stones by optical sorting machines and are rejected. Mr Ska said: “These bottles are recyclable if they go directly in a glassmakers’ oven but when it comes into the chain via collection in municipalities, it is rejected by optical sorting machines or the recyclers. “There is a trend for bottles that stand out on the Continued>>
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Mr Ska,
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Company profile: FERVER
Latest figures show more than 25 billion glass container bottles a year were recycled in Europe.
Some of FERVER’s mem-
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ber companies
Some bottles such as black glass are so dark they are considered stones by optical sorting machines and rejected.
shelf, but this marketing is bad for recycling! The best product for us is a cylindrical bottle, without a label and any colour, but then you have an anonymous product.” Glassmakers have been encouraged to be more aware of their packaging. The recyclability has to be tested before launching a new product For example, a re-sealable cap with wire and ceramic can cause inclusions. Metalised labels can also cause inclusions in a new bottle. But glass, cork, rubber stoppers, crown cork and well-designed aluminium caps are fine and sleeved labels are ideal for glass recycling. Other challenges for recyclers are the design of bottles. Glass bottles with a convex, uneven or embossed shape make it difficult to check for failures on newly produced bottles. RFID tags in labels can also cause inclusions.
Opportunities Mr Ska is positive about the future of glass and of glass recycling. He
believes the general concept of sustainability favours the glass sector compared to other types of packaging. “Some foods that were previously not packaged in glass have been brought back into glass because of the sustainability of the packaging and thanks to the unique tasteless property of glass. “The new Circular Economy has clear targets and clear calculation methods so the wrong reportage to Eurostats will no longer be a possibility. It is certainly an opportunity to promote recycling at a European level. “We are in contact with recyclers and authorities outside of Europe that view Europe as an example of good recycling. Glass is one of the best examples of recycling, so we are an ‘example of the example’. We hope to promote outside of Europe the real recycling of glass.”
FERVER, Brussels, Belgium, www.ferver.eu
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OUR HIGH PERFORMANCE OXY-FUEL FURNACE COMBUSTION SYSTEMS: LOWEST NOX EMISSIONS HIGHER PRODUCT QUALITY ENERGY SAVINGS 2015 installations: 410 270 18 220 24
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Supplier profile: Zippe
A family affair As part of our series of profiles on German suppliers in the run up to glasstec 2016, Sally Love met with Dr. Holger Zippe at the company’s headquarters in Wertheim. As well as being CEO of the family-run Zippe Industrieanlagen he is also President of the VDMA and head of the organising committee for glasstec, and so was able to share his thoughts on the industry’s biggest event. Can you give us a brief history of Zippe? Put in a nutshell, the Zippe company was founded in 1920 by my grandfather Alfred Zippe Senior and his wife Maria, on their wedding day. At that time they worked for the Bohemian glass industry, but after 1945 all this was gone and they left their home in Bohemia and went to Germany. They made their way through Eastern Germany and finally settled in Wertheim. We are happy they settled here, because the location is fantastic for us – we are only 45 minutes from the airport, which is a major asset because we can easily travel all around the world. In 1960, my father Alfred Zippe Jr. built the first automatic batch plant in Germany for a container glass company making bottles in Nienburg. In 1964 we built our first batch plant overseas, and since then it has become a success story. We work worldwide, for glass factories and glass groups whenever they need a batch plant modification or even a new batch plant. We do not get all the orders, but I feel we often get the big, important orders. We have a staff of 200 people, all highly professional and with a lot of experience, however we are still a young team with an average age of 36.
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Does being a family-run company affect Zippe’s core values? Certainly, yes. We have many positive effects from being a family company. One is with all our employees: we work very closely together, with a longterm perspective. We have
z Dr. Holger Zippe, CEO of Zippe, with his son Dr. Philipp Zippe, Managing Partner and COO of the company.
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Supplier profile: Zippe
Where is the majority of Zippe’s business done in the world at the moment?
many people who have been been with us for 30 years, all their working career, and so they have a lot of experience. We work together like a big family: they know my ancestors, we know fathers and sons of theirs, and that’s a very nice community. The core values are also affected in that we look more for the long-term perspective and not for short-term profit. The negative is that maybe we look too little for short-term profit. We perhaps take orders that we should reject… “No, not for this time, not for this amount of money”… But the positive side outweighs this, and when the family works well together with all our employees and our managers it is a very positive situation.
It is always changing. It changes from year to year. At the moment the biggest orders we have are from Europe, Latin America and North america, these are the biggest jobs that we execute. But that can change in a year, easily. South East Asia always remains an important market for us.
That’s good for Europe – often you hear about the market slowing down. Yes, there is still investment in Europe. Europe is more of a mature market, that’s true, so there is not as much growth. But still, companies are changing, locations are changing, situations are changing. The glass industry is where the market is, where the energy is, where the raw materials are, and so locations even change within Europe from time to time. Some factories are closing because they are old and not working efficiently anymore, some new ones are being built, quite often close to the customer where you have little transport – so there is always something going on. New types of glass industry are also being developed such as fibreglass and pharmaceutical glass, which were maybe not produced on the same scale 20 years ago.
Where in the world do you see the most opportunity for future business?
We have 200 employees here in Wertheim and 45 highly qualified technicians in our second production plant in East Germany, where we mostly produce conveying equipment. We also have representatives in 55 countries all around the world, so all the major markets are covered. That’s very helpful, because they know the situation with the customers and can approach them on a level that is much more suitable for them in their respective countries with their respective traditions. Then we have a couple of firmly established companies such as in Italy, China, England or Poland, which help to execute contracts on a larger scale when you have to include local services.
z Zippe’s headquarters in Wertheim, Germany.
How important is the German market to Zippe? The German market is important to us, as we usually have a very constant rate of 15-20% of our turnover coming from customers in Germany. That means we have an export rate of 80-85% of business outside of Germany. Germany has a very dynamic glass industry with many glass factories and is a strong home market, which is certainly an advantage for us. There won’t be new glass factories built every year, not even every three years, but there is still always some investment going on. Continued>>
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How many plants/offices do you have around the world?
Asia is still an important market, and the Americas and Europe continue to be important. In the medium term, the clear answer is Africa: this will be a market of the future. Several countries are coming up very rapidly on the African continent. There is a very simple rule in business that I have experienced over the decades: wherever there is stability, there is investment. It’s very simple. Where there is no stability, there is no investment. You can follow that pattern all over the world. Luckily, in spite of all the difficulties that are happening in the world and the Middle East, and a few countries in North Africa, there are still countries in the world with a lot of stability, and thus there will be investment. Not to forget Iran there will be a lot of demand for new techniques in this country, after years of isolation. We are ready to serve this new market.
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Supplier profile: Zippe
A Zippe batch plant at SGD in France, which began operation at the end of 2015.
Are you currently developing any new technologies or investing in any R&D efforts that you can tell us about? I can’t tell you all the details, but batch and cullet pre-heating will continue to be advanced and will be made more user-friendly. Last year we successfully incorporated and started up at Nampak the first cullet pre-heater that was built overseas and not in Europe, and this gives us hope and confidence for similar cases. Our latest generation of batch chargers, the Vibrotube, is having a lot of success, and so we will continue to develop this system in the future. It combines all the advantages of previous chargers without the disadvantages, which is to say the screws. The screw charger is always a disadvantage because it has a screw which needs to be replaced from time to time, and the Vibrotube doesn’t have that. That is another example of sound development. Also, user-friendly and more advanced control systems with more management information capabilities – this is another area that we are strongly focused on.
“Not to forget Iran - there will be a lot of demand for new techniques in this country, after years of
”
isolation.
First of all, it is by far the largest glass show in the world. It has a variety of exhibitors, and the glass industry itself showcases its products there, especially in terms of flat glass. It also has a broad range of technology suppliers to the glass industry, which is equally important. All the key technology suppliers are at glasstec, with large booths that show real machinery – at least partly. We cannot build a batch house at glasstec; it would be larger than one of the halls! Ultimately, it’s a great place to come together and it’s conveniently located. It is firmly established in people’s minds – people are in the habit of going there every two years, at around the same time. There are other events organised around it, such as conferences, but the main thing is that you have all the big exhibitors there. Every glass person should be there, for two days every two years. That’s how we see it.
What does your role as President of the VDMA entail in general? Do your duties increase in a glasstec year? I have been President of the VDMA for six years now, and the role entitles you to be the head of the organising committee on the board of glasstec. During a glasstec year there is a lot more work than in normal years, because you have to prepare meetings and make decisions such as how the opening events will look. Of course, Messe Dusseldorf prepares all of this very professionally, but they also need the advice and the assistance of the board. It’s a great role, and I’m happy to fulfil it. It’s very demanding and very challenging, but you always grow with your challenge.
Zippe, Wertheim, Germany. www.zippe.de
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In your view, what are the most pressing challenges and opportunities facing the glass industry at the moment? It’s always the same: glass has a certain weight, and glass breaks. These are the two disadvantages, the comparatively heavy weight and the ability to break. Everything else speaks for glass – there is no other disadvantage. It is probably not more expensive than other packaging materials, it does not react with any of its contents, which is a fantastic ability especially in food packaging, and its transparency is great. Energy consumption is also a big factor, so cullethandling systems need to be more advanced in the future. These are the biggest challenges.
You are President of the VDMA, which of course supports glasstec. What is it about the show that makes it so important to the glass industry?
z Zippe’s Vibrotube batch charger.
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Lubrication
Swabbing Robot lubricant success Dirk Jongers* and Francois Breye** discuss how a lubricant has helped replace the manual operation of the swabbing of blank moulds during the glassmaking process.
ANNEALING LEHRS
T
he hollow glass market has to catch up on new technologies to achieve a higher efficiency and reach customers’ expectations. A lot of innovation has already taken place, but there is still a lot to do. In this context, a huge contrast exists: highly automated IS machines are, usually, still operated with manual swabbing to lubricate the moulds. Belgian company Socabelec, known in the glass industry for turnkey automated production lines, developed an automatic spray system for Heye International. The spray system efficiently replaces the manual operation of swabbing the blank moulds. However, it only succeeded in meeting the required results with the development of a specially designed lubricant by the Belgian company VDV Lubricants: the Glassline SwabMatic 180. Based on their respective know-how in the glass industry, the two companies have demonstrated that the machine and appropriate lubricant can generate substantial results: zero rejects from swabbing, no need for section stops, a 75% saving on lubrication consumption and improved operator safety. Recent on-site testing on a Heye IS machine – NNPB process/ light bottles, has proven these results and the glass plant was happy to see a higher production output within the specifications.
HOT-END COATING
Challenges Beside the automation approach, it was challenging for VDV Lubricants–Glassline to develop the appropriate lubricant. The combination of know-how present in the Glassline product range for manual swabbing and the technical team of the company, have contributed to a successful conclusion to the project. Lubricating the blank mould is a specific process and requires the following criteria: a good friction coefficient between glass and mould, stable in time, and something non-polluting and safe for the operator. An additional requirement for automatic swabbing was to have a formulation able to be efficiently sprayed on the blank mould surface. Glassline SwabMatic is formulated with a combination of oils, solids and additives. VDV Lubricants and Glassline will now, in partnership with Socabelec, further update the Glassline SwabMatic accordingly to other types of process such as blow/blow, press/blow and others.
*Director, VDV Lubricants/Glassline **Sales & Technical Manager, VDV Lubricants/Glassline, Baasrode, Belgium francois.breye@vdv-lub.com www.glassline.be www.socabelec.com
Glass International March 2016
COLD-END COATING
Belt Cleaning Brush • Belt and spindles tempering lines • Decorating lehrs • Chemical tempering ovens • Roller annealing lehrs • Mold pre-heating kilns • Stackers + cross conveyors • Scraper conveyors • Cullet crushers • Thermal shock test systems Contact us: vidromecanica@vidromecanica.com
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History
Prof. John Parker Turner Museum of Glass and ICG
The SGT: 100 not out!
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ast year the ovenware product Pyrex celebrated its centenary and Coca Cola’s iconic bottle was first patented in 1915. The same year Wes Turner began a mission to revolutionise the UK Glass Industry, which led to the formation of the Society of Glass Technology (SGT). Wes Turner was born in 1881 in Wednesbury, West Midlands to William and Blanche Turner, the second of seven and their first son. His father, a man of strong Christian principles, was at various times a railway porter, signalman, ironworker, postman and insurance agent. Against the odds, including polio at three, Turner excelled, receiving accolades at school and progressed to higher education in Birmingham, a Chemistry BSc in 1898, a Masters degree and the Erhardt research prize. In 1904 he was appointed assistant lecturer in Physical Chemistry at the University of Sheffield. Characteristically his first observation was the lack of order in its chemical stores. His organisational skills quickly remedied this. He was keen to apply his knowledge to industrial processes and began lecturing to local metallurgists, even offering evening classes. He wrote on science and industry in the local press (1909) and became President of the Sheffield Society of Applied Metallurgy (1914). World War 1 began in July 1914. Following Turner’s suggestion to his vicechancellor, the University commissioned a scientific advisory committee in September 1914 to help manufacturers adapt. Inevitably he was appointed secretary. WW1 also proved a wake-up call to the UK glass industry which had become moribund, relying on secret recipes passed down the generations and unable even to measure furnace temperature. The sudden lack of imports from the continent required them to: extend their product range, particularly in laboratory ware and optical components; source raw materials domestically;
and adapt their technologies. Firms in Rotherham, Mexborough and Barnsley were quick to seek help and Turner was quick to respond. In May 1915 a report on ‘The Glass Industry in Yorkshire’ proposed that a centre for research and teaching on glass manufacture be created. In June the proposal became a reality, led by Turner. The Department of Glass Manufacture soon became the Department of Glass Technology, the first in the world. Unusually it was administered by a ‘Glass Research Delegacy’, with members from both the university and industry, not by the University Council. The freedom this gave Turner meant he was not always popular with his academic colleagues but ‘then orthodoxy would have been a serious handicap to a man of Turner’s foresight and drive for innovation’ (Douglas). He particularly appreciated the lack of a direct telephone line to the Vice Chancellor. Turner soon strengthened his links to industry by creating ‘the SGT’, which first met formally in November 1916. Wisely the SGT selected its first president from industry, Frank Wood of Wood Brothers, Barnsley, with Turner as secretary. Its aim was to strengthen collaboration not only between academia and industry but also between its industrial partners. Turner perceived that these inward looking firms shared many problems best solved by working collaboratively. The SGT offered a forum for frank discussion of common issues. From 1917 it was enhanced by adding a library, an information database and publishing transactions of meetings and research proceedings in its Journal of the Society of Glass Technology. Early issues remain an amazingly rich source of knowledge, both the physical chemistry of making glass and its properties. The SGT still maintains this philosophy and is this year celebrating its centenary with an international conference and several colloquia (www.sgt.org).
After the war Turner, with almost missionary zeal, began contacting international glass experts. In the 1920s he was negotiating with Prof Gehlhoff of the DGG in Germany, and others in the USA, France, Belgium, Italy and Spain. Reciprocal conferences and factory visits became almost commonplace and in 1933 led to the foundation of the International Commission on Glass (ICG), still active and represented in 33 countries (www. icglass.org). During these visits, Turner acquired a substantial Glass Art collection, often pieces created uniquely for him, or experimental samples by eminent artists. In 1943, he donated it to the university, where it forms the Turner Museum of Glass. He also received many awards (e.g. OBE, FRS, DSc) and yet more from overseas. Even after retiring (1945) he remained active until his death in 1963. By 1955 the university was pursuing fundamental research alongside industrial trouble shooting, and this entailed different funding streams. To solve the associated administrative issues, the British Glass Industries Research Association (BGIRA), now Glass Technology Services (GTS), was created and housed in a new building next door. In 2003 they moved to Chapeltown, Sheffield. The SGT now shares the same home. Professor Turner’s legacy is enormous and retains an ability to adapt in a changing world. Here’s to the SGT’s bicentenary! r
Bibliography R W Douglas, Biographical Memoirs of Fellows of the Royal Society, Vol. 10 (Nov., 1964), pp. 325-355 F J Gooding & E Meigh, Glass and WES Turner, Published by the SGT, 1951
*Curator of the Turner Museum of Glass, Sheffield University, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk
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British Glass
AllGlass and GTS created pellets that have been successfully tested in a commercial furnace.
Glass Technology Services
Small is useful The glass on the left was made using normal batch materials, the glass on the right from pellets.
When you’re measuring cullet in millimetres or microns it’s too small to be recycled, right? That’s been common wisdom until now. However, a partnership between AllGlass and Glass Technology Services, funded by Zero Waste Scotland, has come up with a more environmentally and financially friendly answer.
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llGlass, Scotland, produces more than 15,000 tonnes of glass beads annually for a host of applications including reflective highway paint, blast media and water filtration. However, the process creates huge quantities of residual glass powder. This can theoretically be used in bricks, concrete, fillers and tiles, but all these uses demand a specific powder size and grading fine powder isn’t economically viable for these markets. Nor is it easy. In fact, this powder clogs and wears out machinery – and with much of it below 100 microns, anyone exposed to it needs to consider PPE. There’s no chemical reason it can’t be re-melted, but, again, the handling properties are poor. The powder can float up rather than dropping into the melt, and as it recirculates with the hot air it coats and potentially blocks regenerators and ducting or heads up the chimney to damage filters. So, despite its potential value this glass usually ends up in landfill. Geoff Crutchley at AllGlass has been working on ways to use it: “If we could just find a way to handle it mechanically, this could become cullet for re-melt, reducing CO2 emissions, dependence on raw materials and energy use.” It is not hard to understand the impetus: each tonne of cullet returned to a glass furnace saves 246kg of CO2 and uses 322kWh less energy to melt (compared to the use of raw materials). Pelletised cullet has the potential to further improve energy savings – previous studies have suggested that up to 15% less
energy is needed to produce glass from pelletised materials. “Our approach was to form the powder into pellets of around 1cm diameter, making it easier to handle, store and transport. We started on our own lab bench – mixing the powder with liquid and a binding agent, pressing it into pellets and then drying it,” Geoff recalled. “The Zero Waste Scotland grant meant we could work with Glass Technology Services to scale up, automate.” Having previously worked on pelletisation research, GTS brought experience of extrusion, injection and pan pelletisation, along with its analytical and melting facilities. This allowed the technique and recipe to be refined – reaching the optimum point for pellet quality, production speed and quantity of binding agent needed. “Too much binding agent pushes the cost right up; too little and the pellets disintegrate,” Geoff explained. “But with GTS’s expertise we arrived at a recipe and process that means we can efficiently produce pellets with a decent crush strength.” Allied Glass Containers volunteered to let a batch of the pellets go through its commercial furnace. “We’d done enough trials with our test furnace to be certain the pellets wouldn’t cause any problems,” said Chris Holcroft, who leads the GTS team. “But it’s still a big ask to put them through a commercial furnace worth tens of millions of pounds. We were incredibly grateful for Allied’s faith in the project. The pellets, of course, did us proud: there
was no disruption to the process or the product quality.” “We expect that the pellets can be produced at a cost that’s comparable to the price of cullet,” said Geoff. “So, given that we could create several tonnes of these pellets every day from our residual powder, that’s a significant potential carbon saving for a glass manufacturer. The next step for us is to confirm the machinery capacities quoted for full-scale production and line up customers.” Chris explained how GTS is keen to explore wider use of pelletisation. “Cullet for re-melt generally has to be in pieces of at least 10mm because smaller cullet is so difficult to screen for nonmelting contaminants such as ceramics. Anything less than 10mm tends to go to aggregate use – or landfill. “But, milling the cullet to less than 1mm, so contaminants do melt, is a plausible solution if the glass powder can be pelletised effectively and economically.” GTS is also investigating the potential for combining filter dust and other fine raw materials with the cullet in pellets to improve the handling of these materials. “That could make thousands of tonnes more glass available for re-melt every year – which would be a step towards the glass industry’s decarbonisation goals.” Chris said.
Glass Technology Services, Sheffield, UK. enquiries@glass-ts.com www.glass-ts.com AllGlass, Renfrewshire, Scotland UK www.allglass.uk.net Zero Waste Scotland www.zerowastescotland.org.uk
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53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce, 6 Tel +39 0577 304730 ifv@fonderievaldelsane.com
www.fonderievaldelsane.com
Case study: Verallia Bad Wurzach
Verallia installs synchronous reluctance
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pecial rules apply to the industrial production of packaging glass, because the quantities required are high and the production sites must keep up with demand. The process does not allow for any downtime so the systems are in operation 24/7, all year long. The compressed air and vacuum supply is also subject to extremely high requirements. Numerous compressors and vacuum pumps are installed in Verallia’s plant at Bad Wurzach, Germany. They work in three networks: 4 bar, 6 bar and a vacuum network, as is typical in hollow glass production. The compressors and pumps generate compressed air and vacuum for the production of around 2.5 million bottles per day. The start of the process involves several sumps, which each store around 300 tonnes of molten glass at a temperature of approximately 1600oC – and they do so 24/7. During production itself, precisely proportioned red-hot glass droplets are ‘shot’ through glass channels to create hollow glass every second. In doing so, the compressed air presses the hot mass into the mould and the vacuum pulls the molten glass on to the mould walls (Fig. 1). The compressors in the extensive compressed air station look very different due to their year of manufacture, rather than their brand: in Bad Wurzach, Wittig rotary vane compressors were installed more than 50 years ago. The oldest system, which is still in operation, dates to 1965. It has been in operation for 50 years and is still used as a redundancy machine (Fig. 2).
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The rotary vane principle This explains the commitment to the principle of the rotary vane compressor, which was patented in 1908 by Karl Wittig. Wittig was the first company to apply the multi-cell principle. A rotor is mounted eccentrically in a cylindrical housing. The slotted rotor contains moveable vanes that divide a crescent-shaped working chamber into cells with changing volumes. Gas and centrifugal forces press the rotor vanes against the wall of the housing, enabling air or gas to be taken in, compressed and discharged. The low speed of 1500 rpm, the low rotor weight
z Fig 2. Several rotary vane compressors dating back to between 1965 and 1975 are in use at Verallia Deutschland.
and the low amount of moving parts all help to ensure a long service life with minimal maintenance requirements. As a result, rotary vane com-pressors are extremely durable even when used 24/7, as evidenced by the 50-year-old machine at the Verallia plant. The rotary vane compressors, with performance ranges of 250 to 6000m³/h or 30 to 710kW, are developed and produced at Gardner Denver, in Schopfheim.
The energy-conscious user Energy efficiency is important at all of Verallia’s production sites. In particular, this also applies to compressed air and vacuum generation, which makes up a considerable proportion of the energy consumption of the plant. Siegfried Heinrich, Head of the mechanical maintenance department, responsible for compressed air supply at Bad Wurzach said: “The compressed air network requires around 55,000 - 60,000kWh of electrical energy per day, while vacuum generation requires less than 15,000kWh.” To generate the required amounts of air economically, all newer compressors are equipped with regulated speed drives. The compressors and vacuum pumps in the three networks are regulated according to demand via the self-programmed PLC. Continued>>
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Fig 1. A look at glass production at Verallia.
technology
Verallia’s Bad Wurzach plant was the first to test drive technology for Gardner Denver’s rotary vane compressors, from the Wittig brand. Bernd Haas* reports on the results obtained, which demonstrated an increased efficiency and lower energy consumption compared to previous machines.
Not only are Siegfried Heinrich and his colleagues valued clients for Wittig, they also make excellent partners when it comes to the further development of the machines. Verallia has consistently provided Gardner Denver with suggestions for improvement, which is relatively easy to implement as the Gardner Denver Wittig rotary vane compressors are custombuilt. Produced in Schopfheim with a high degree of vertical integration, the production paths are kept short. For example, the sound hood was optimised at Verallia’s request, so that all components of the compressor can be accessed as quickly as possible in the event of maintenance or repair.
benefit all involved? The idea became a reality. The operating parameters of the new compressor at Verallia (with the ‘old’ drive) were precisely recorded over several months. They then switched to the synchronous reluctance motor and continued the measurements (Fig. 4). The result is a comparison of both drive systems under identical conditions. And, in theory, it is better than they had hoped. Henrik Bräutigam, ABB Automation Products, stated: “The calculations indicated a 0.8% advantage in terms of the degree of efficiency of an IE4 reluctance motor in comparison with a regulated speed IE3 motor. This is the value specified in our documents. However, the measurements showed that the efficiency was improved by 1.5%.”
Implementing the drive technology The newest compressor in the compressor station has a regulated speed of RO 170 with 132kW drive (Fig. 3), which supplies up to 1408m3/h of compressed air into the 4 bar network. The ROW compressors are standard compressors in many operations that require continuous compressed air. They are equipped with three-phase asynchronous motors and frequency converters from ABB. After Verallia ordered the ROW 170, ABB approached Gardner Denver with a new drive concept. At that point, the company had developed synchronous reluctance motors that worked with a higher degree of efficiency than conventional three-phase motors and was ready to start production. They are ranked in efficiency class IE4 and can be used together with conventional ABB converters. When launching such innovations, all system manufacturers are faced with the same dilemma: many users want to use energy-saving technology, but nobody wants to be the ‘guinea pig’, particularly when there are no practical comparative values available and the benefit is not clear. So, a collective idea arose: a new energy-saving drive concept for rotary vane compressors was available. As was a manufacturer of compressors that wanted to use the concept, along with a highly active and critical user. Why not come together to carry out a practical test that would
Advantages
Fig 3. The first Wittig rotary vane synchronous reluctance motor with an IE4 efficiency class.
The reduced energy consumption is not the only advantage of the new drive. Mr Bräutigam stated: “There is no slip during operation in the synchronous machine. This means that the motor, and thereby the entire machine, runs more quietly. The rotor does not produce any losses and less waste heat is generated. When it comes to compressors this is an important factor, because heat promotes bearing wear. As a result, we also expect that the maintenance intervals of the compressor bearings will be increased.” Furthermore, the motor only runs under partial load with 80 to 85% of the full load. This is where the degree of efficiency of the reluctance motor is at its best – and therefore the wear is low, as the motor is never run at its performance limits. Another major advantage of the synchronous reluctance motors is their compact design: the fitters at Verallia in Bad Wurzach were able to replace the drives 1:1, as the new drive fitted in the existing sound hood. This means that users of Gardner Denver Wittig rotary vane compressors can also upgrade their old regulated speed machines, which are still equipped with IE1 and IE2 motors, to benefit from increased efficiency and Continued>>
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e
Case study: Verallia Bad Wurzach
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Case study: Verallia Bad Wurzach
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z Fig 4. The drive was replaced 1:1 because it requires no more space than a regulated speed asynchronous motor.
retrofit a reluctance motor. Even the control technology poses no problems: a new programme simply needs to be installed onto the existing ABB converter (Fig. 5).
GUARANTEED* performance where the glassmaker needs it most.
Conclusion
z Fig 5. The existing converter (left) is still used and simply required new software.
Bernd Haas *Manager Sales Systems, Gardner Denver, Schopfheim, Germany. www.gardnerdenver.com Verallia, Bad Wurzach, Germany www.verallia.com
*Subject to technical specification, terms and conditions System 500 forehearths and distributors are offered with guarantees covering temperature stability, thermal homogeneity and fuel consumption. Are yours?
z Fig 6. The stars of the comparative test from left to right: Bernd Haas, Manager Sales Systems of Gardner Denver Schopfheim, Siegfried Heinrich, Head of the mechanical maintenance department at Verallia Deutschland and Henrik
PARKINSON-SPENCER REFRACTORIES LTD Holmfield, Halifax, West Yorkshire, UK. HX3 6SX Tel: (44) (0) 1422 254472 • Fax: (44) (0) 1422 254473 Email: admin@parkinson-spencer.co.uk • www.parkinson-spencer.co.uk
Bräutigam, ABB Automation Products.
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The comparative test was conclusive for ABB and Gardner Denver: with a payback period of much less than two years, the synchronous reluctance drive is a competitive alternative to the well-known asynchronous motor. The test also impressed those responsible at Verallia (Fig. 6). They have already ordered the next rotary vane compressor for the Bad Wurzach plant and it is currently being produced in Schopfheim. Needless to say, it is equipped with an IE4 synchronous reluctance motor from ABB.
PSR System 500 Forehearths and Distributors.
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Refractories
Recycling refractories Mike O’Driscoll* discusses how the recycling of refractories is entering a new era, with the rise of secondary raw materials becoming a dominant factor.
That equates to a lot of mineral deposit exploration, development, mining, processing, and trading by mineral suppliers, and a lot of sourcing, buying, and logistics activity by refractory raw material purchasers. Research by IMFORMED has shown that refractories ranks 10th out of 26 leading markets for industrial minerals, consuming as many as 24 different industrial minerals. Certain key refractory minerals, such as andalusite, bauxite, fused alumina, graphite, dead burned and fused magnesia, silicon carbide and zircon, have experienced and continue to experience supply chain issues. These issues include: Limited development of commercial scale resources; overreliance on leading sources, which have local issues that impact supply (China in particular, which is responsible for 40-90% of refractory mineral supply to global users); inconsistent quality and supply availability; and pricing and logistics issues. Such factors are a nightmare for refractory raw material purchasers (Fig. 2). Refractory mineral purchasers are therefore seeking alternative raw material sources. With the rapidly evolving
Continued>> Source refractory waste from end user eg. alerted to break-out
Circle of refractory life Refractory recycling in simplified stages Refractory product manufactured and sold to end user
Crushed, dried, screened, iron removal
Fig. 1: Circle of refractory life.
On-site assessment and price negotiation of spent refractories
Extract spent refractories and transfer to processing plant
Packed, stored ready for sale to refractory manufacturer (or other end user)
The industrial minerals market In spite of declining specific refractory consumption (10-15kg/t steel; 3kg/t nonferrous metal; 1kg/t cement; 4kg/t glass), around 35 million tonnes per year of refractory raw materials are consumed to make refractories worldwide.
refractories recycling sector, it will soon become the ‘new normal’ for refractory mineral purchasers to be offered a menu of their mineral requirements which will comprise two distinct and competitive refractory mineral sourcing options: Primary and secondary raw materials (SRM). While it is true that processing spent refractories demands certain processing and sorting requirements that are not necessary for mainstream primary mineral processing, it is clear that in recent years these challenges have been increasingly met. Certain mineral processing companies have now developed a niche in mineral recycling, and in particular, processing refractory minerals from spent refractories. Such companies include: DEREF, Italy; Harsco Metals & Minerals, UK REF Minerals, Latvia; Refra-System, Hungary; TYMO Engineering, Germany; Valoref, France; LKAB Minerals, UK; Mineralen Kollée, Netherlands; Horn, Germany. This is expected to be a growing trend, with more players emerging in the near future. There is also likely to be more
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T
he recycling of refractories has been around for at least three decades, although it has only been in the last few years that the sector has witnessed increased commercial activity. The primary driver has been the gathering momentum of a zero waste culture across the spectrum of industrial manufacturers, which include refractory users such as steel, non-ferrous metal, cement, and glass plants. This trend not only helps to find a much needed, environmentally-friendly solution for spent refractories, but also helps to conserve mineral resources, energy consumption, and the overall cost of refractory production, as well as minimising the expense of landfill costs for end users. The movement has received an additional boost from the development of relevant processing and quality control techniques, such as Laser Induced Breakdown Spectroscopy (LIBS), and in Europe from the much-lauded circular economy promotion driven by the European Commission through a variety of initiatives. The upshot is that waste refractories will be just one of a range of secondary raw material resources– along with, for example, steel slag, fly ash, waste water, glass, paper, plasterboard, and red mud – from which the recycling of minerals hosted by these industrial wastes are to play a much more significant role in the future of the industrial minerals trade. The era of secondary raw material (SRM) supply is upon us (Fig. 1).
Using hand or automated sensor technology, sort by chemical composition, fines, unrecyclable waste; composition analysed, segregation
Initial crushing of shapes to 200400mm sizes
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Refractories
Refractory classification BASIC
Industrial mineral
Main chemical
Primary source
(incl. synthetic)
component
country
Dead burned magnesia
85-99.8% MgO
China
Fused nagnesia
97-99.8% MgO
China
Dead burned dolomite
56-62% MgO, 36-40% CaO
USA
Chromite
>46% Cr2O3
South Africa
Sintered/fused spinel
66-80% Al2O3, 21-33% MgO
China
Olivine
ACIDIC
40-50% MgO, 34-45% SiO2 Norway
Calcined alumina
>99.5% Al2O3
China
Fused alumina
94-99.5% Al2O3
China
Calcined bauxite
85-88% Al2O3
China
Sintered/fused mullite
40-75% Al2O3
USA
Andalusite, sillimanite, kyanite
60-65% Al2O3
South Africa
Refractory clays
20-45% Al2O3
China
Pyrophyllite
20-30% Al2O3
South Korea
High alumina
Low alumina
Silica SPECIALISED
Quartzite, silica sand
>97% SiO2 Regional
Fused silica
>99.8% SiO2 USA
Zircon
66% ZrO2+HfO2 Australia
Zirconia
>99% ZrO2
China
Silicon carbide
>93% SiC
China
Graphite
75-99% C
China
INSULATING
Diatomite
>75% SiO2 USA
Perlite
65-80% SiO2
China
Vermiculite
45% SiO2
South Africa
z Fig. 2: Refractory mineral summary table. attention given to recycling refractories by the leading refractory manufacturers and end users.
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Future use of SRMs Steel producers are already turning their attention to refractory recycling. For example, Italy’s Acciai Speciali Terni has teamed up with Deref to develop a zero waste strategy in recycling refractories and slag. However, it remains a case of ‘early days’. In his UNITECR 2015 presentation, Melvyn Bradley, Technical Director of LKAB Minerals, UK, acknowledged that despite LKAB’s involvement in the refractory recycling market for many years (formerly as Minelco Minerals with Richmond Refractories): “Customer feedback has highlighted the need to improve the quality of the recycled refractory material, meaning investment in more advanced processing equipment and further development work on the use of reclaim material in the finished product.” In general, refractory SRM now appear to be more widely accepted in the refractories industry than previously. Europe is ahead of the pack globally, although Asia and North America are starting to pick up the baton. Precise figures for refractory SRM, or refractory ‘recyclate’ are hard to ascertain, and published figures vary. Where refractory SRM is likely to find a major market is in refractory products that have less stringent performance
requirements, but where price remains a significant factor. Typical waste refractories that can be recycled include firebrick, mid-alumina brick, bauxite brick, alumina-carbon, alumina-magnesia and magnesia-carbon bricks. While the use of recycled aggregate in mag-carbon bricks is now common practice, according to Bradley the level of free metals remaining from anti-oxidant additions is key to preventing quality issues with new bricks. Typical applications for aluminosilicate SRM include medium range castables and precast shapes. Recycled alumina-mag and mag-carbon can be used for tundish spray and furnace gunning repair products. Other potential uses of refractory SRM include alumina-silicate SRM as a bauxite replacement in secondary ladle treatment, and mag-carbon SRM used as a slag conditioner in EAF. In addition to providing SRM for refractory manufacture, spent refractories can become raw materials for powder coating applications, metallurgical additives, slag conditioners and feedstock for cement.
Refractory recycling outlook There is no doubt that refractory recycling is going to see an increase in attention and activity. Owing to the potential large volumes of refractories for recycling and the fact that end users and refractory manufacturers are unlikely to invest in
their own recycling plants, it is expected that an increasing number of refractory recycling processors will enter the market in the near future. Chief among the trends and developments of this growing sector will be the evolution of a new supply chain of refractory SRM which will usher in new players whose roles will include waste refractory sourcing, recycling, processing/sorting equipment supply, logistics, marketing and purchasing.
Key trends to monitor: r More and improved automation systems, particularly in refractory waste sorting; r Development of mobile sorting systems; r Research in refractory additives, such as microsilica, to improve the performance of products based on refractory SRM; r Development of pelletisation of refractory SRM fines for use in other applications, such as slag conditioning; r Development of new refractory formulations to enhance/ease their successful recyclability; r Increased establishment of long term strategic alliances and partnerships between sources of spent refractories (end users), refractory recyclers and refractory manufacturers in both sourcing waste refractories and buying refractory SRM; r Education of refractory end users (eg. steel producers) to positively engage in and recognise the benefits of refractory recycling, including reasonable prices for the sale of refractory waste; r Clarification and universal (eg. EU) establishment of clear legislation, regulations, and licences regarding handling, processing and trade in refractory waste and refractory SRM. r
IMFORMED is organising the Mineral Recycling Forum 2016, 14-15 March 2016, Rotterdam focusing on the SRM supply chain including refractories, and MagForum 2016, 9-11 May 2016, Vienna, focusing on magnesia supply and demand including refractories. *Mike O’Driscoll, Director, IMFORMED Industrial Mineral Forums & Research Ltd Market research and specialist conferences for the industrial minerals business mike@imformed www.imformed.com
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GLASS HAS A GREAT PAST.
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Refractories
Analysis of glass defect compositions from AZS refractory Peter Ĺ imurka provides an analysis of glass defect compositions originating from AZS refractory during tableware glass production.
A
fused cast Alumina Zirconia Silicate (AZS) is a commonly used type of refractory material in the glass industry. It has a remarkable resistance to corrosion in the glass melt and glass melting environment.
Determining the origin Despite its advantages, the presence of the glassy phase in the AZS refractory is a problem. While there can be many sources of cord defects, refractory contamination in glass is frequently cited as a leading source. Glass contamination can and does occur from the exudation and corrosion of superstructure and glass contact fusion-cast AZS refractories. The glassy phase exudation from fused cast AZS can occur at high temperatures due to the expulsion and the runoff of a
Al2O3, K2O
A database of 69 chemical compositions of defects, mainly cords, has been created by collecting the final products containing glass defects during regular tableware glass production in a period of 48 months. These products were collected due to the observation of high defect presence in daily production. The products came from different furnaces in which glass melt with the same glass composition was prepared. The composition of glass defects in wt. %, analysed by EDX analysis on a commercial basis by Glass Service, Czech Republic, are in Table 1. These compositions are ordered from the highest to the lowest value of the Continued>>
Al2O3
35
30
30
25
25
20
20
wt, (%)
wt, (%)
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35
Glass defect database
part of the glassy phase at the surface of the refractory. The corrosion of refractory materials in contact with the glass melt causes the formation of a boundary layer that is enriched in the components of the refractory material. When this boundary layer ends up in the bulk of the melt, it forms a knot or a cord. To eliminate a cord defect problem in industrial glass production, an indication of the origin of the cord in the furnace is helpful. The aim of this paper is to show the analysis of glass defect compositions originating from AZS refractory during tableware glass production. To identify a potential source of inhomogeneities, the chemical composition of the cords was combined with results of the AZS refractory corrosion study presented in [1, 2].
15
15 10
10
5
5
0
0 0
10
20 Al2O3,
30
40 50 Number K2O Al2O3,(glass)
60
70
80
0
5
10
15
20
25
30
35
40
Number Al2O3,
K2O (glass)
Fig 1. Content of Al2O3 and K2O in glass defects ordered from the highest to the
Fig 2. The content of Al2O3 in glass defects ordered from the highest to the
lowest value of Al2O3 (wt. %).
lowest value, Al2O3 >5.0 (wt. %).
40 Glass International March 2016
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Refractories
C aO
ZrO2 BaO
1 12.82 32.15 47.44 5.62 0.78 0.83 0.36 2 8.47 30.3 49.90 9.98 0.29 0.55 0.79 3
10.75 25.33 52.10
7.99
4 11.20 25.2 51.93 7.73
0.96
1.8
1.82
1.4 1.50 1.59
5 10.78 23.11 54.32 7.59 1.55 0.83 1.81 6 10.77 22.67 53.80 7.64 1.60 1.73 1.81 7 9.57 22.66 55.41 7.96 2.12 0.59 1.81 8 10.83 22.8 53.59 7.18 2.86 1.00
2
9
10.48
17.70
61.77
7.14
1.43
1.47
10
8.70
16.56
63.00
8.23
1.94
1.57
11
8.73
16.39
63.13
7.85
2.5
1.85
12
9.66
16.19
62.29
7.55
2.29
2.3
13
8.49
15.74
64.05
7.76
2.16
1.81
14 10.00 15.60 58.67 5.48 6.24 1.29 2.72 15 8.68 15.32 64.92 7.67 1.78 0.15 1.50 16 9.37 15.1 63.37 7.63 1.57 1.2
2.5
17 8.48 14.59 65.50 7.80 2.11 0.07 1.57 18 9.47 14.56 63.07 7.61 1.90 2.32
1.5
19 8.99 14.31 62.29 6.60 4.41 1.25 2.14 20
9.50
14.23
64.46
7.48
2.14
2.20
21 9.64 13.91 61.66 7.47 3.88 1.2
2.43
22
1.83
8.40
13.80
65.42
23 10.32 13.61 56.96
7.94
2.61
8.97
3.28 3.80
3.7
24 9.61 13.41 63.71 7.72 2.83 0.77 1.94 25
9.1
13.19
66.00
26 9.54 12.73 65.31
7.64
2.2
7.4
2.12 0.82 2.47
2.14
27 9.68 12.57 60.73 6.86 2.73 5.15 2.29 28
8.24
12.54
65.89
7.81
3.21
2.30
29 9.88 12.13 64.49 6.99 2.59 1.92 2.00 30 9.58 11.86 63.92 7.45 2.74 2.56 1.89 31 8.99 11.8 67.47 6.80 3.20 0.23 2.25 32 8.88 11.67 65.70 7.16 3.85 0.43 2.31 33 9.93 11.26 66.04 6.82 3.16 0.53 2.26 34 10.0 10.6 65.8 6.6 2.3 2.6 2.2 35 9.48 10.6 66.53 6.915 2.52 2.27 2.23 36 8.97 10.4 63.54 6.86 3.46 4.44 2.69 37
8.55
9.93
67.84
7.33
3.95
2.4
38 8.67 9.74 67.09 6.81 4.38 0.47 2.83 39 10.5 9.42 66.42 6.84 3.8 2.62 1.56 40 9.99 9.32 62.18 6.12 3.20 6.4 3.13 41 9.99 9.23 65.11 6.44 5.54 0.59 3.10 42 9.32 9.19 67.77 7.3 2.97 1.9 2.63 43 8.8 8.88 68.02 7.28 4.19 0.80 2.76 44 9.83 6.89 69.27 6.67 4.92
2.42
45 9.84 6.73 69.03 6.26 4.59 0.93 2.63 46 10.48 6.55 65.11 5.64 4.69 3.78 3.71 47 10.64 5.50 68.47 5.77 5.85 0.49 3.28 48 11.12 5.00 70.64 5.40 4.77 0.00 3.45 49 10.93 4.42 69.30 5.62 5.94 0.83 2.96 50 10.14 4.00 70.42 5.97 5.27 0.00 4.19 51 10.36 3.17 69.61 5.60 6.81 0.50 3.96 52 10.46 2.72 69.67 5.31 7.31 0.59 3.94 53 7.63 2.42 72.64 5.31 7.52 0.00 4.47 54 10.51 1.70 73.91 5.20 5.53 0.00 3.77 55 10.12 1.70 74.35 5.23 5.26 0.00 3.96 56 10.64 1.68 72.98 5.22 5.53 0.00 3.95 57 9.10 1.59 71.62 5.47 8.30 0.21 3.72 58 10.76 1.57 69.86 5.27 7.94 0.17 4.42 59 10.10 1.50 75.33 5.18 4.81 0.00 3.52 60 10.54 1.47 70.73 5.50 7.80 0.00 4.42 61 10.22 1.45 73.10 5.32 5.69 0.00 4.22 62 10.17 1.21 71.87 5.20 7.53 0.00 4.10 63 10.26 1.17 71.43 5.16 7.63 0.00 4.34 64 9.73 1.13 74.00 5.52 5.47 0.00 4.17 65 10.00 1.20 74.27 5.39 5.55 0.00 3.79
Al2O3 content. The composition of glass surrounded glass defects, which is presented in Table 1 (Glass), was determined as the average value from an analysis of 30 samples. The composition of the glassy phase in non-used AZS 32 refractory material (AZS glass phase) was calculated as the mean from the analysis in four different locations of a sample.
Results The detailed analysis of the individual oxide content in the glass defects presented in[1], revealed that there are pairs of cords with comparable chemical composition; they differ mainly by the presence of ZrO2 (Table 1, e.g. No 18&20, 25&26, 44&45). As the cords of the pairs with and without ZrO2 content have all the other main oxides close to each other, we can say that these cords originate from the same kind of source. A cord originating from the AZS refractory glassy phase may not contain ZrO2; the content of other oxides, mainly K2O, plays an important role in determining the cord origin. Fig. 1 shows the Al2O3 and K2O content in glass defects, ordered from the highest value to the lowest value of Al2O3. The red line represents the level of Al2O3, the green line is the content of K2O in the glass surrounding the knots and cords (Glass). It was shown that there are chemical compositions of the cords (Table 1, defects No 54-69), where the difference of the Al2O3 content is not higher than 0.5 wt. % in comparison with its content in the original glass. Simultaneously, the content of other oxides is not far from their content there. It is possible to say that the origin of these defects is not in the AZS material. Possible reasons for their creation can be incorrect batch weighing and/or mixing, incorrect granulometry of raw materials, unsuitable cullet, evaporation of alkali from the glass melt surface and so on. The cords originating from AZS refractory material are characterised by a higher amount of Al2O3 and
66 9.52 1.00 75.30 5.26 5.25 0.00 3.68 67 9.29 0.97 75.44 5.37 5.12 0.00 3.82 68 10.32 0.85 71.59 5.30 7.72 0.00 4.23
î Ł Table 1. Chemical composition of cords, glass
69 9.18 0.79 73.38 5.43 7.30 0.00 4.74
surrounded defects and AZS refractory glass phase
Glass 10.6 1.2 71.5 5.3 7.1 0.0 4.4
(wt. %).
AZS glass 2.6 17.6 77.0 0 0.5 1.1 0 phase
Continued>>
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No Na2O Al2O3 SiO2 K2O
41 Glass International March 2016
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Refractories
simultaneously higher content of K2O in comparison with their content in bulk glass. Fig. 2 shows where the Al2O3 content is ordered from the highest to the lowest value in glass defects and Al2O3 >5.0 (wt. %), where four groups of defects are identified: – content of Al2O3 30.3 - 32.2 %, 22.8 25.3 %, 8.9 – 17.7 % and 5.5 – 6.9 %. The results showed that the AZS glass phase located above the glass melt is characterised by the content of Al2O3 about 30 wt. %, while the content of Al2O3 is about 22-25 % in the part below the metal line. There was no boundary layer observed.
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Analysis The corrosion mechanism of superstructure involves indiffusion of alkali species (both vapour phase and batch dust particles) from the furnace atmosphere, which causes dissolution of the AZS crystalline alumina phase. In many cases, most of the crystalline zirconia may be retained as a spongy mass upon the refractory surface, and the expanded volume of alkalialuminosilicate liquid phase simply drain out of it. This expanded volume of liquid phase on the refractory surface then runs down to the glass bath under the force of gravity[3]. When we look at the composition of glass defects No 1 and No 2, we can see that there is content of Al2O3 higher than 30 wt. % and they are enriched by alkali oxides (12.82 % of Na2O – No 1 and 9.98 % K2O – No 2). These facts indicate the glass defects originate from the AZS refractory – a part above the metal line. The bubble forming mechanism appears to be the key for the glass defects originating from fused cast AZS where refractory is in contact with a glass melt[4]. Bubbles, which are formed in the AZS glass phase due to compensation of charge of alkali ions by diffusion of electrons in the material, squeezed a part of the glass phase into the bulk of the glass. In the case that there is no boundary layer the composition of the formed cords is close to the composition of the AZS glass phase. The content of Al2O3 in glass defects of the Group 2 (No 3 – No 8) is from 22.8 to 25.3 wt. %. Comparing these glass defects with the composition of AZS refractory glass phase in the part below the metal line[1] indicates that these cords came from this
Day Na2O Al2O3 SiO2 K2O CaO ZrO2 BaO 31st 10.93 4.42 69.30 5.62 5.94 0.83
2.96
32nd 9.84 6.73 69.03 6.26 4.59 0.93
2.63
57th 9.93 11.26 66.04 6.82 3.16 0.53
2.26
Table 2. Chemical composition of cords collected soon after the beginning of campaign in wt. %.
part of refractory. Another potential source of defects is in the saturation boundary layer, which is created during the furnace campaign in the glass/refractory interface of the working or melting part of the furnace. The corrosion mechanism of AZS refractories in a tableware glass melt consists of diffusion of alkalis (Na, K, Ca, Ba) from the glass melt into the refractory, dissolution of the Al2O3 and ZrO2 in the glass phase, diffusion of Zr and Al from the refractory into the glass melt, creation and erosion of the boundary layer area[2]. The figures of created boundary layers are presented in[1,2]. Bubbles, created in the interface, squeezed a part of interface layer into the bulk of the glass. Another source of defects is the boundary layer, which is involved into the glass melt due to the erosive action of the flow of molten glass when it is combined with an erosive action of the flow of molten glass. Table 2 shows the compositions of the glass defects, collected in production after the beginning of campaign – in the 31st, 32nd and 57th days of production. As we supposed that the source of glass defects is a boundary layer that is created by the mechanism mentioned above, the creation of the boundary layer can be seen from the change of content of individual oxides in glass defects. Originally there was 1.2% of Al2O3 in the glass melt and 17.6 % of Al2O3 in AZS refractory glass phase. We can see that due to the dissolution of the Al2O3 in the glass phase and diffusion of Al from the refractory into the glass melt, the content of Al2O3 is increasing continuously to 4.4%, 6.7% and 11.3%.
Conclusion
r The boundary layer of the melting or working part is the source of the other cords.
Acknowledgements This publication was created in the frame of the project ‘Industrial research for reaching more effective melting and forming technology of tableware glass’, ITMS code 26220220072. r
References [1] Šimurka P., Kraxner J., Vrábel P., Pauco T.: Corrosion of AZS Refractories – Source of Defects in Tableware Glass, 13pp., Proceedings of the 76th Conference on Glass Problems, 2-5 November 2015, Columbus, Ceram. Eng. Sci. Proc., to be published 2016. [2] Šimurka P., Kraxner J., Vrábel P., Pauco T.: Mechanism of AZS Refractory Corrosion in Barium Soda Lime Potassium Silicate Glass Melt, 5pp. Scientific.net, Key Engineering Materials (Trans Tech Publications), to be published 2016. [3] Selkregg, K.R., Gupta A.: Knots: Analysis and Minimisation in HighQuality Glasses Ceram. Eng. Sci. Proc. 23 (2002), 59. [4] Dijk, Van F.A.G.: Glass Defects Originating from Glass Melt/Fused Cast AZS Refractory Interaction. PhD thesis, Eindhoven University of Technology (1994).
Peter Šimurka, Joint Glass Centre of the II SAS, Trencín, Slovakia psimurka@gmail.com www.sav.sk
The analysis of glass defect compositions originating from AZS refractory during tableware glass production showed: r The cords with the content of Al2O3 about 30 wt. % come from the part above glass level; r The cords with the content of Al2O3 about 22-25 wt. % originate from the AZS material from melting part located below the metal line;
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Inspection
Improving the quality of hollow glass through inspection Elroy Garza* talks us through the latest developments in inspection equipment and software at Iris Inspection Machines, including advances that match up to the precise requirements stipulated by luxury glassware producers.
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T
he world of hollow glass is moving at a rapid rate. Every year there are vital improvements in quality, design, processes and inspection, all to increase consumer safety. The high standards demanded today by the glass industry have expanded all around the globe thanks to internationalisation and global standardisation within various aspects of hollow glass production. Also, consumer safety has become a human right with even developing countries demanding better quality. Every year, new non-government organisations that defend consumer safety are created in developing countries. Inspection quality and standards, which verify the safety of each produced bottle, have evolved at the same rate as the market itself. The market is evolving rapidly in terms of bottle shape, colour, size, design and complexity of the logo. Today, the equipment that Iris Inspection Machines has developed can detect visual and non-visual hazardous defects, literally ‘zooming’ to detect even smaller defects. These improvements include modern optical capacities, which allow inspection and analysis of each bottle at a 360° angle in high resolution. The latest electronic and software developments help the machine learn by itself what it is to reject and what it is to keep, and the MultiModel software allows the Evolution machine to inspect up to seven different articles at the same time (Fig.1). The Selector software detects bottle deformation, height and several other dimensions, and many other developments that Iris’ R&D department is working on (Fig.2). It accurately inspects all kinds of critical and noncritical defects while giving glassmakers
z Fig1. Multi-Model inspection screen on the Evolution 12 with 6 different articles (height, shape, size, etc.) on the same line.
extra plant efficiency. Apart from unveiling important hardware and software improvements for its established Evolution 12 and Evolution 5 non-contact inspection machines, Iris has also developed equipment that addresses the precise requirements of luxury glassware producers, requiring the highest levels of perfection. The standalone Evolution Ultimate and Evolution Dim models provide additional helpful features to users of the Evolution series of non-contact, camera-based inspection machines.
Transparent inspection Evolution Ultimate has been conceived to identify transparent faults in high quality asymmetric flacons and the complexshaped articles required for perfumery, cosmetics, premium liquor and luxury applications, as well as high quality tableware. Typical defects detected include loading and compression marks, transparent surface blisters, cat scratches, orange peel,
cold mould, laps and tears, and wash boards (Fig.3). Despite the advances made in noncontact glass container inspection technology in recent years, existing machines have been unable to provide the quality of transparent defect inspection required by the glass industry’s high-end producers. As part of an ongoing research and development programme, the Evolution Ultimate solution has been conceived to meet this demand by engineers at Iris Inspection machines. It incorporates a refined optical solution to detect defects as small as surface blisters and tiny imperfections created by swabbing lubricants. One of France’s leading glass perfumery specialists has worked with Iris engineers to perfect the Evolution ultimate concept. This provides an automated on-line inspection solution compared to previous Continued>>
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Inspection
and maximum finish external diameter, finish height, height of the finish ring and finish flatness (Fig.4). The machine is equipped with dedicated optics allowing precise measurements. The machine is also equipped with HD cameras and an HD screen, with a user-friendly interface built for the machine. The hardware and software are compatible with other Evolution machines, sharing the same spare parts and software.
z Fig 2. Internal measurement recognition with
z Fig 3. Low contrast defect (orange skin) detect-
the Selector software.
ed with the Evolution Ultimate.
z Fig 4. Inspection zone for finish external diameter, finish height and finish flatness with Evolution Dim.
skilled but labour-intensive methods. This innovation was made possible by incorporating the latest advances in cameras, light source and lens technology, combined with intelligent software improvements. Similarly, specialist pharmaceutical glass producers have benefitted from the surface inspection capabilities provided by this equipment, helping to identify thin surface blisters that have the potential to cause contamination problems or personal injuries, both within the body of a container or externally, unless detected before reaching the client.
Measurement solution Also available is a solution for the online geometrical measurement of pharmaceutical and perfumery glassware, providing the benefits of unseen precision. Evolution Dim equipment provides the advantages of non-contact inspection, no rotation and 360째 vision on the production line. Although Evolution 12 incorporates
some aspects of dimensional measurement, its performance is not as precise as required by some luxury glassmakers. Evolution Dim has been developed to satisfy these needs more accurately, incorporating an innovative optical system and four cameras (three for the sidewall and one specifically for the finish) to take precise measurements on the external profile of the finish as well. It is possible to measure accurate article height, for example, as well as minimum and maximum diameters, roundness and barrelling. Defects detected include tiny body deformations, non-round sidewall, diameter deformation or other minor geometrical defects on the body, bulged or sunken sidewalls, and out-ofspecification height. Evolution Dim calculates the verticality of each container to measure the body or finish shifting. Defect examples include lean articles, offset finish and bent neck. The dedicated finish camera integrates the accurate measurement of minimum
The Evolution range has evolved and has a new PC, larger HD touch screen (21.5in), HD cameras and new software. Within its newly designed processing unit, Iris has reduced maintenance costs via the new design and assembly employed. There are fewer components in the PC itself and direct access to the HDD (Hard Disk Drive) is provided on the front panel. Improved cooling is another important feature. The 21.5in high definition screen provides quicker accessibility to different screens, less switching between screens, the instant display of parameters, faster adjustments, quicker optimisation and easier fine-tuning. The screen permits the full display of high-resolution images taken by highresolution cameras with no need to zoom. This provides a realistic view of containers and faults, better detection of small faults, and an improved understanding of machine behaviour. The high-resolution cameras are 400% more powerful than before, providing sharper and more accurate images as well as improved discrimination between different types of defects (e.g. small stones and blisters), better definition of container shapes and excellent dark glass inspection capabilities. The cameras also feature higher dynamics in terms of noise interference, thereby improving the quality of the image provided. Iris therefore believes that the Evolution equipment is fast, powerful and user-friendly, offering enhanced, precise inspection of glass containers. Retrofit kits are available for all existing Evolution machines. r
*Area Sales Manager, Iris Inspection Machines, Bron, France www.iris-im.com
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Vision for inspection
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Plant technology
A production monitoring solution SIL2016 has been released by Vertech’, a company dedicated to software solutions for the glass manufacturing industry. Here, Marie Cens* outlines this year’s updates and developments.
T
he SIL is a modular system that provides tools for controlling the entire production process of a glass making factory, from the forming machines through to the palletisers. It features production performance follow-up; quality control management; final product control capabilities; pallet resorting follow-up; management of mould set performance; data mining; structured and comprehensive reporting tools; raw materials control management and a plant performance dashboard. Vertech’ invested around 25% of its annual turnover into developing web applications and added new inspection machines that are available on the market to the list of the equipment that can communicate with the SIL solution. New SIL developments are compatible with glass processes such as the press and blow process, press ware, tubing/ drawn glass and decoration lines. The SIL2016 solution can address the food and beverage, perfume, cosmetics and pharmaceutical industries with the goal of improving plant efficiency.
Fig 1. An example of an event form, used to indicate what actions the operator has taken.
historical events, with the option of selecting the level of details they wish to see. Therefore the history view has been improved and can now be used as the basis for daily production meetings. Managers can see necessary information, on a single view, with required details available in tooltips, displayed as they place the mouse on the events. SIL2016 also includes many improved production features, quality control features and mould solutions now compatible with multi-article production configuration. Last year, Vertech’ introduced the smart Dashboard (Fig. 2), which displays the main Key Performance Indicators ata-glance. This year, Vertech’ introduced SILXchange (Fig. 3), an intranet portal dedicated to production that has new
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Latest developments The new SIL version can not only trace production events, but also the actions performed by the operators when a critical defect is seen or a systematic rejection is started or stopped. Operators are used to reacting to these types of events, but up until now the actions carried out were not recorded. Thanks to automatic event forms (Fig. 1), they are now able to indicate what corrective and/or preventive actions were done in reaction to these events. SIL2016 is also able to highlight repeated defects on a cavity or a mould number. A warning alerts the operator when repeated defects are seen at the end of their control. As the SIL production monitoring system has become more accurate and displays more information about production events, it is important for managers to have an overall view of
Fig 2. The Dashboard, launched in the SIL2015 version.
Fig 3. The SILXchange is an intranet portal that allows different users to have different KPIs saved to their profiles.
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Plant technology
widget library management. With SILXchange, Vertech’ has designed groups of users for whom the plant manager can decide what information to display. With SILXchange, each user has their own dashboards and KPIs saved to their profile. Finally, the new data extraction tool presented at the last glasstec, the SILDataXtractor (Fig. 4), has evolved and offers multiple possibilities for data extraction. The tool is based on a new concept: all searches are made depending on the date, whatever the job, the line, the article produced or the mould. The user-friendly tool provides many filters and pivot tables to organise the data as you wish. Results are displayed in easy-toread advanced charts and historical views.
A new year Vertech’ releases a new version of its software each year, in order to respond to clients requirements to have homogeneous versions in the different factories of a same glass group. That way, developments performed during the year are compiled and proposed in the next version, allowing relevant improvements to be installed in every other plant that has its system upgraded. This also allows Vertech’ all the time necessary to test the new developments, before releasing the software version with the best possible quality.
PRESSURE AND VOLUME TESTING IN ONE MACHINE. The most advanced volume and pressure measurement system available today.
Benefits Production management software is dedicated to increasing plant performance and Vertech’ believes the benefits generated outweigh the cost of the solution itself. A production monitoring system is a tool that concentrates all production data and displays KPIs in real time, and a management dashboard to pilot the plant with more efficienct and secure data. But it is also a reporting tool, performing analyses and a quality tool ensuring traceability of several years. After 20 years of expertise in software solutions dedicated to the glass industry, Vertech’ has evolved the SIL production monitoring system into an ideal tool to make the link between production equipment and management of the factory. r
*Marie Cens, Sales and Marketing, Vertech’, France http://vertech.eu
Fast throughput Fig 4. The SILDataXtractor is the company’s latest data extraction tool.
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Global Combustion Systems Total Support Unit 43, Evans Business Centre, Easter Inch, Bathgate EH48 2EH, Scotland, UK Tel+44 (0) 1506 657310 Fax +44 (0) 8704 799975 Email Sales@globalcombustion.com Web www.globalcombustion.com
Airfield Business Park, Elvington, York, YO42 4AU, UK Tel: 0044 1904 608999 Email: sales@sheppee.com Web: www.sheppee.com
SCREEN PRINTING
13:53:19
DECORATING MACHINES KBA-KAMMANN GmbH Bergkirchener Str. 228 D-32549 Bad Oeynhausen (Germany) Fon +49 (0) 5734 5140-0 Fax: +49 (0) 5734 5140-5130 mail@kba-kammann.com www.kba-kammann.com
FLEXIBLE. PRECISE. INNOVATIVE.
RAW MATERIALS Rio Tinto Minerals 2 Eastbourne Terrace London W2 6LG, UK Tel +44 (0) 207 781 1450 Fax +44 (0) 207 781 1851 Email: simon.cook@riotinto.com Web: www.riotintominerals.com
Glassman events visit: www.glassmanevents.com
3/10/16 9:57 AM
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studiobrand.it
A great vintage stays forever. This year we are celebrating 110 years together, while looking forward to exciting new challenge for the time to come. Thank you for trusting and believing in our love for tradition, passion and innovation. Your trust and loyalty are our success.
1906-2016 110th anniversary Melting | Forming | Automation | Energy
All in one www.bdf.it
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05/02/16 12:37